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Abstract:

A first substance is separated from a flowable primary substance flow by
mixing and precipitation in a separating device. The mixing binds the
first substance and at least one magnetic carrier particle to each other.
In the precipitation, the carrier particles contained in the primary
substance flow, including the bound first substance, are separated by
magnetic forces into a residual primary substance flow depleted of the
first substance and a secondary substance flow enriched with the first
substance. By varying a parameter which influences the magnetic forces in
a predetermined manner during the precipitation, the content of the first
substance in the secondary substance flow and/or in the residual primary
substance flow is influenced. Based on the change of the content of the
first substance caused by the variation due to the predetermined
variation, at least one parameter of the separation method is set.

Claims:

1-17. (canceled)

18. A method for separating a first substance from a primary substance
flow by a separating device, comprising: mixing the first substance and
at least one magnetic carrier particle until bound to each other as a
bound first substance; precipitating the at least one magnetic carrier
particle contained in the primary substance flow by separating the bound
first substance, using magnetic forces, into a residual primary substance
flow depleted of the first substance and a secondary substance flow
enriched with the first substance; varying a parameter which influences
the magnetic forces in a predetermined variation during said
precipitating, such that a content of the first substance in the
secondary substance flow and/or in the residual primary substance flow is
influenced by said varying; and determining a change of content of the
first substance in the secondary substance flow or in the residual
primary substance flow that is caused by the variation; and setting at
least one parameter of the separation method based on the change of the
content depending on the predetermined variation.

19. The method as claimed in claim 18, wherein said determining, in
addition to the change of the content depending on the predetermined
variation, determines the content of the first substance for the
secondary substance flow and/or for the residual primary substance flow,
and wherein said setting of the at least one parameter of the separation
method also is based on the content of the first substance.

20. The method as claimed in claim 19, further comprising setting
parameters of said mixing.

21. The method as claimed in claim 20, wherein said setting of the
parameters of the mixing increases a magnitude of the change of the
content of the first substance depending on the predetermined variation.

22. The method as claimed in claim 21, wherein a previously determined
change of the content depending on the predetermined variation is used as
a reference value.

23. The method as claimed in claim 22, further comprising: repeatedly
specifying the change of the content of the first substance depending on
the predetermined variation; checking whether the change of the content
of the first substance depending on the predetermined variation is
greater in magnitude than the reference value; and replacing the
reference value by the change of the content of the first substance
specified depending on the predetermined variation, if the reference
value is smaller in magnitude than the specified content change depending
on the predetermined variation.

24. A method for separating a first substance from a primary substance
flow by a separating device, comprising: demixing the first substance
bound to a magnetic carrier particle to detach the first substance from
the magnetic carrier particle; precipitating carrier particles contained
in the primary substance flow by separating the carrier particles, using
magnetic forces, into a secondary substance flow enriched with magnetic
carrier particles and a residual primary substance flow enriched with the
first substance; varying a parameter which influences the magnetic forces
in a predetermined variation during said precipitating, such that a
content of the first substance in the secondary substance flow and/or the
carrier particles in the residual primary substance flow is influenced by
said varying; and determining a change of content of the first substance
and/or the carrier particles in the secondary substance flow or in the
residual primary substance flow that is caused by the variation; and
setting at least one parameter of the separation method based on the
change of the content depending on the predetermined variation.

25. The method as claimed in claim 24, wherein said determining, in
addition to the change of the content depending on the predetermined
variation, determines the content of the first substance in the secondary
substance flow or the carrier particles in the residual primary substance
flow, and wherein said setting of the at least one parameter of the
separation method also is based on the content determined.

26. The method as claimed in claim 24, wherein the content of the first
substance in the secondary substance flow is determined and/or the
content of the carrier particles in the residual primary substance flow
is determined.

27. The method as claimed in claim 26, further comprising determining the
content of the first substance and/or of the carrier particles in the
primary substance flow.

28. The method as claimed in claim 27, wherein said setting of the
parameters of the demixing reduces a magnitude of the change of the
content of the first substance in the secondary substance flow depending
on the predetermined variation.

29. The method as claimed in claim 28, wherein the first substance is one
of a non-magnetic ore and a DNA sequence.

30. The method as claimed in claim 29, wherein the primary substance flow
is one of an ore-bearing sludge and a solution containing DNA sequences.

31. A control unit for a device for separating a first substance from a
primary substance flow, comprising: a memory storing machine-readable
program code including control instructions; and a processor executing
the control instructions to perform a method including mixing the first
substance and at least one magnetic carrier particle until bound to each
other as a bound first substance; precipitating the at least one magnetic
carrier particle contained in the primary substance flow by separating
the bound first substance, using magnetic forces, into a residual primary
substance flow depleted of the first substance and a secondary substance
flow enriched with the first substance; varying a parameter which
influences the magnetic forces in a predetermined variation during said
precipitating, such that a content of the first substance in the
secondary substance flow and/or in the residual primary substance flow is
influenced by said varying; and determining a change of content of the
first substance in the secondary substance flow or in the residual
primary substance flow that is caused by the variation; and setting at
least one parameter of the separation method based on the change of the
content depending on the predetermined variation.

32. A device for separating a first substance from a primary substance
flow, comprising: a demixing unit and/or a mixing unit; a precipitation
unit; and a control unit, having an active connection to the
precipitation unit and the demixing unit and/or the mixing unit, the
control unit including a processor executing control instructions to
perform a method including demixing the first substance bound to a
magnetic carrier particle to detach the first substance from the magnetic
carrier particle; precipitating carrier particles contained in the
primary substance flow by separating the carrier particles, using
magnetic forces, into a secondary substance flow enriched with magnetic
carrier particles and a residual primary substance flow enriched with the
first substance; varying a parameter which influences the magnetic forces
in a predetermined variation during said precipitating, such that a
content of the first substance in the secondary substance flow and/or the
carrier particles in the residual primary substance flow is influenced by
said varying; and determining a change of content of the first substance
and/or the carrier particles in the secondary substance flow or in the
residual primary substance flow that is caused by the variation; and
setting at least one parameter of the separation method based on the
change of the content depending on the predetermined variation.

33. A non-transitory computer readable storage medium embodying
machine-readable program code that when executed by at least one
processor performs a method comprising: mixing the first substance and at
least one magnetic carrier particle until bound to each other as a bound
first substance; precipitating the at least one magnetic carrier particle
contained in the primary substance flow by separating the bound first
substance, using magnetic forces, into a residual primary substance flow
depleted of the first substance and a secondary substance flow enriched
with the first substance; varying a parameter which influences the
magnetic forces in a predetermined variation during said precipitating,
such that a content of the first substance in the secondary substance
flow and/or in the residual primary substance flow is influenced by said
varying; and determining a change of content of the first substance in
the secondary substance flow or in the residual primary substance flow
that is caused by the variation; and setting at least one parameter of
the separation method based on the change of the content depending on the
predetermined variation.

34. A non-transitory computer readable storage medium embodying
machine-readable program code that when executed by at least one
processor performs a method comprising: demixing the first substance
bound to a magnetic carrier particle to detach the first substance from
the magnetic carrier particle; precipitating carrier particles contained
in the primary substance flow by separating the carrier particles, using
magnetic forces, into a secondary substance flow enriched with magnetic
carrier particles and a residual primary substance flow enriched with the
first substance; varying a parameter which influences the magnetic forces
in a predetermined variation during said precipitating, such that a
content of the first substance in the secondary substance flow and/or the
carrier particles in the residual primary substance flow is influenced by
said varying; and determining a change of content of the first substance
and/or the carrier particles in the secondary substance flow or in the
residual primary substance flow that is caused by the variation; and
setting at least one parameter of the separation method based on the
change of the content depending on the predetermined variation.

Description:

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application is the U.S. national stage of International
Application No. PCT/EP2012/060296, filed May 31, 2012 and claims the
benefit thereof. The International Application claims the benefit of
European Application No. 11170688 filed on Jun. 21, 2011, both
applications are incorporated by reference herein in their entirety.

BACKGROUND

[0002] Described below is a method for separating a first substance from a
flowable primary substance flow by a separating device, the method
including mixing and precipitation. In the mixing, the first substance
and at least one magnetic carrier particle are bound to each other. In
the precipitation, the carrier particles contained in the primary
substance flow, including the bound first substance, are separated by
magnetic forces into a residual primary substance flow depleted of the
first substance and a secondary substance flow enriched with the first
substance. Also described is a method for separating a first substance
from a flowable primary substance flow by a separating device, the method
demixing and precipitation. In the demixing, the first substance bound to
a magnetic carrier particle is detached from the magnetic carrier
particle. In the precipitation, the carrier particles contained in the
primary substance flow are separated by magnetic forces into a secondary
substance flow enriched with magnetic carrier particles and a residual
primary substance flow enriched with the first substance. Also described
is an associated device for performing such separation processes, a
control unit, machine-readable program code, and a data storage medium
containing machine-readable program code.

[0003] The relates to the technical field is separation technology as used
in mining operations for the extraction of non-magnetic ores, for example
and also the field of medical device-assisted diagnosis for e.g. the
selective separation of specific DNA segments.

[0004] In the context of mining, the objective is usually to separate
valuable substances from non-valuable substances. This separation is
usually effected with the aid of a flowable substance mixture which
contains both the valuable and the non-valuable substances. By treating
or conditioning the valuable substances in a corresponding manner, e.g.
selective hydrophobing of the valuable substances in the sludge, these
can be removed from the sludge using, e.g. air bubbles or carrier
particles.

[0005] In the case of non-magnetic ores, use is made inter alia of
magnetic carrier particles which are also preconditioned accordingly.
These bond selectively to the non-magnetic valuable substances. By virtue
of the non-magnetic valuable substances then adhering to magnetic carrier
particles, they can be isolated from the sludge by magnetic forces.

[0006] Such a method is disclosed in the US patent document U.S. Pat. No.
4,225,425, for example. The document describes a method in which magnetic
carrier particles are added to mineral ores. The ore, including the
magnetic carrier particles, is then precipitated in a porous
ferromagnetic matrix by magnetic forces.

[0007] WO 2010/031681 A1 also discloses a separation method, in which
magnetic carrier particles are separated by magnetic forces from a
substance flow and the non-magnetic ores remain in the substance flow.

[0008] Such methods are similarly used in other technical fields (e.g.
biotechnology); see the German patent document DE 697 36 239 T2, for
example. In this case, e.g. specific viruses are bound to a magnetic
carrier particle in order to isolate this from an aqueous solution.

[0009] Such separation methods using magnetic carrier particles are also
employed in other technical fields, e.g. water and effluent engineering,
the paper industry and further technical fields. Owing to the fact that
both the substances to be selected and the carrier particles can be
conditioned such that they selectively adhere to each other, this
technology can be used for almost any technological separation techniques
and substances.

[0010] Critically in such separation methods, particularly with regard to
their efficiency, it is not generally known what proportion of the
substances to be selected is actually bound to the carrier particles and
what proportion is still "free" in the solution (i.e. not bound to a
carrier particle). Depending on the application, the user might
specifically want the carrier particles to be bound to the first
substance, or might specifically want the carrier particles and first
substance to be present separately.

SUMMARY

[0011] By implementing a method of the type in question, a device for
separating a first substance from a flowable primary substance flow, a
control unit, a data storage medium containing machine-readable program
code, and machine-readable program code by which operational efficiency
can be increased, thereby increasing economic efficiency and conserving
the resources that are used.

[0012] Described below is a method that provides information about the
"process state" by using the change of the content of the first substance
depending on the variation of the parameter influencing the magnetic
forces. In particular, the change of the content of the first substance
depending on the predetermined variation can be used as a basis for a
further setting of the method parameters, thereby increasing the economic
efficiency. The change of the content of the first substance in the
residual primary substance flow or in the secondary substance flow
depending on a predetermined variation of the magnetic field can be used
as a measure of how effectively the first substance contained in the
primary substance flow is bound to the magnetic carrier particles. If the
variation of the magnetic precipitation forces causes little or no
variation of the content of the first substance in the residual primary
substance flow or in the secondary substance flow, this shows that the
first substance is insufficiently bound to the magnetic carrier
particles. It is thus possible to provide information about the "process
state", i.e. "how well the process is functioning".

[0013] The magnetic forces may be generated electromagnetically. In this
case, the predetermined variation can be generated by influencing a
current flow using coils, for example. This allows the magnetic forces to
be varied in a selective, simple and repeatable manner. It is also
possible to vary the geometric arrangement in the precipitation in order
to change the magnetic forces causing the precipitation, and thus to
achieve a corresponding and desired variation of the magnetic forces.

[0014] By determining the change of the content depending on the
predetermined variation, it is possible to set at least one parameter of
the separation method, in particular at least one parameter of the mixing
and/or at least one parameter of the precipitation. The magnitude of the
change of the content depending on the predetermined variation may be
used as a criterion on the basis of which the at least one parameter of
the separation method is set. The variation of the magnetic forces may be
controlled by a control unit. The repeatability and hence the accuracy is
thereby increased when specifying the "process state".

[0015] The method can be used whenever a first substance has to be
separated from a flowable substance mixture, irrespective of whether the
first substance is a waste substance, harmful substance, useful substance
or valuable substance. The use of resources is reduced by virtue of such
an approach, since use of the method ensures that less of the first
substance is contained in the residual primary substance flow while the
expense of preparation (bonding the first substance to the carrier
particles) is minimized.

[0016] In an embodiment of the method, in addition to determining the
change of the content depending on the predetermined variation, a content
of the first substance is determined for the secondary substance flow or
for the primary substance flow, and at least one parameter of the
separation method is also set on the basis of the content. While the
change of the content depending on the predetermined variation is
primarily useful for the purpose of inferring the quality of the mixing,
the determination of the content of the first substance makes it possible
to infer, either in absolute or relative terms, how well the separation
of the first substance from the primary substance flow functions overall
or, in the case of a specific mixture result, in respect of the bonding
of the first substance to the carrier particles. In the context of the
method presented above, a minimal content of the first substance is
usually desired in the residual primary substance flow, while a maximal
content is desired in the secondary substance flow. Since the mass in
respect of the first substance remains the same during the processing,
i.e. the mass of the first substance in the secondary substance flow plus
the mass of the first substance in the residual primary substance flow is
equal to the mass of the first substance in the primary substance flow,
the content of the first substance can be determined in the secondary
substance flow and/or in the residual primary substance flow.

[0017] In particular, the determination of the content of the first
substance and the change of the content of the first substance depending
on the predetermined variation makes it possible to identify which of the
partial method operations should be optimized. If, e.g., a low content in
e.g. the secondary substance flow is determined, yet a high change of the
content depending on the predetermined variation is determined, it can be
inferred that the mixing is functioning well, i.e. the first substance
has been effectively bound to the carrier particles, but the
precipitation should be optimized, usually by changing the (geometric
and/or magnetic) deposition conditions.

[0018] The determination of the change of the content depending on the
predetermined variation and the determination of the content also make it
possible to specify a suitable sequence in which the partial processes
should be optimized. For example, if the determined content is low and
the magnitude of the change of the content depending on the predetermined
variation is also low, it is appropriate to optimize the mixing first,
rather than the precipitation.

[0019] This exemplary combination of content and content change resulting
from a predetermined variation shows that the mixing is not working
effectively. This is evident because the change of the content depending
on the variation is low. This means, since the change of the content is
low for a predetermined variation, that little of the first substance is
bound to the carrier particles. However, a high content of first
substance in the secondary substance flow requires that the first
substance should also be bound to the carrier particles, since otherwise
no precipitation of the first substance using magnetic forces is
possible. It follows that the bonding of the first substance to the
carrier particles must be improved first, before the content is then
optimized by setting parameters of the precipitation. However, if the
change of the content depending on the variation is high (e.g. above a
specific reference value, in particular a threshold value), yet the
content of the first substance in the secondary substance flow is low,
this means that the first substance has bound effectively to the carrier
particles, but the precipitation parameters in the precipitation must be
adapted in order to increase the content.

[0020] A calibration and/or setting of the parameters of the mixing and
the precipitation, providing as far as possible optimized parameter
values, may take place in a first phase of the separation method and
productive separation of the first substance from the primary substance
flow only takes place in a productive phase which follows the calibration
phase. The first phase is used to identify economically effective
operating parameters and/or parameter values. This setting of the
parameters in the calibration phase can be done e.g. on the basis of
reference values, in particular threshold values, for the change of the
content of first substance in the secondary substance depending on the
predetermined variation of a parameter which influences the magnetic
forces flow and/or possibly for the content of the first substance in the
secondary substance flow. In particular, it is advantageous to feed the
generated secondary substance flow and residual primary substance flow
back into the primary substance flow during the calibration phase. This
prevents any material loss of the first substance, thereby further
improving the economic efficiency of the method.

[0021] When the optimization and/or calibration is complete, the
separation method is switched into the productive phase, in which
economically efficient separation of the first substance from the primary
substance flow can then be effected using as far as possible optimal
parameter settings for the partial processes.

[0022] The parameters may be set, in particular the parameters of the
mixing, in particular in the first phase or calibration phase, by
repeatedly and preferably continuously determining the change of the
content depending on the predetermined variation of at least one
parameter of the separation method, and modifying the parameters such
that the magnitude of the change depending on the predetermined variation
is increased. This preferably takes place under approximately constant
deposition conditions of the first substance. In particular, the same
variation of the parameters influencing the magnetic forces is preferably
performed in each case.

[0023] Provision is preferably made for setting the parameters of the
mixing. These have a significant influence on the economic efficiency of
the separation method. Parameters of the mixing are considered to include
any boundary conditions that can be predetermined or set in respect of
the mixing process. These include e.g. the mixing energy, in particular
shear energy or shear rate of the mixer, the mixing duration, the mixing
means used (i.e. that which achieves the mixing), the concentration of
magnetic carrier particles used, in particular depending on the present
concentration of the first substance, the rate at which magnetic carrier
particles are added to the primary substance flow, the addition rate and
concentration used to cause the first substance to bond to the magnetic
carrier particles, e.g. hydrophobing agent, the proportion of liquid or
solid in the primary substance flow, etc.

[0024] The parameters of the mixing are preferably set in such a way that
the magnitude of the change of the content depending on the predetermined
variation is increased, in particular for a predetermined content. This
means that the bonding of the first substance to magnetic carrier
particles is improved, whereby the separation becomes more economically
efficient using the same predetermined variation, since an increased
proportion of the first substance can now be precipitated as a result of
optimizing the precipitation.

[0025] A previously determined change of the content depending on the
predetermined variation is preferably used as a reference value. It is
thereby possible during the precipitation of a specific substance to
create comparable parameter settings or to continuously optimize the
reference value such that the economic efficiency of the method is
further improved. The reference value is preferably set to the maximum
that was previously achieved during the precipitation of a specific
substance, i.e. in the past, in respect of the magnitude of the change
depending on the predetermined variation. It is thereby ensured that the
process improves continuously and that almost constant optimal operation
of the separation unit is achieved.

[0026] A change of the content depending on the predetermined variation is
preferably specified regularly, preferably continuously, checking whether
the change of the content depending on the predetermined variation is
greater in magnitude than the present reference value and, if the
reference value is smaller in magnitude than the specified content change
depending on the predetermined variation, the reference value is replaced
by the specified content change depending on the predetermined variation.

[0027] Described below is a method for separating magnetic carrier
particles from a first substance, which was previously bound to the
magnetic carrier particles, in a manner which is economically efficient
and conserves resources. The method can be used whenever a first,
non-magnetic substance in a flowable substance mixture has to be
separated from a magnetic substance, irrespective of whether the first
substance is a waste substance, harmful substance, useful substance or
valuable substance.

[0028] In addition to determining the change of the content, provision is
advantageously made for determining a content of the first substance in
the secondary substance flow or of the carrier particles in the residual
primary substance flow, and for setting at least one parameter of the
separation method on the basis of the determined content as well. The
explanations given above in respect of determining and using the content
apply similarly. The content of carrier particles in the residual primary
substance flow allows the method to be controlled in such a way that only
a specific content of carrier particles is contained in the residual
primary substance flow. This has a direct effect on the economic
efficiency of the method, since carrier particles that are still
contained in the residual primary substance flow can usually only be
removed therefrom at considerable expense if they have already passed
through the precipitation unit and cannot be fed back into it. However,
since magnetic carrier particles are required for continuous execution of
the method and for a "load method" in particular, i.e. the bonding of a
non-magnetic first substance to magnetic carrier particles for the
purpose of removing agglomerates including carrier particles and
particles of the first substance from a flowable primary substance flow,
the magnetic carrier particles have to be replaced, and must therefore be
purchased subsequently and supplied to the method. It is also
advantageous to determine the content of the first substance in the
secondary substance flow and to set parameters of the method, in
particular parameters of the precipitation, on the basis of this content,
since if first substance and carrier particles are present concurrently
but are not bound to each other, the content of first substance in the
secondary substance flow can be influenced by the deposition conditions.
This is because the magnetic forces influence the movement of the carrier
particles, and the first substance may in turn be dragged along by or
physically enclosed by the carrier particles depending on the influence.
Therefore the content of the first substance in the secondary substance
flow can be used for setting the precipitation parameters. In particular,
the parameters of the precipitation unit can be set on the basis of the
determined content (and assuming that the agglomerates have been demixed
correspondingly) in such a way that the content of first substance in the
secondary substance flow is minimized, particularly if a minimal flow
rate has been predetermined for the secondary substance flow.

[0029] Provision is preferably made for additionally determining the
content of the first substance and/or the carrier particles in the
primary substance flow. It is thereby possible to determine how
effectively the precipitation is working. The proportion of magnetic
carrier particles in the primary substance flow (i.e. in a mass flow
direction before the precipitation) and then in the residual primary
substance flow can be determined by a measuring entity, for example. The
approach in this context is to maximize the difference between the
primary substance flow and the residual primary substance flow in terms
of the content of magnetic carrier particles, and to minimize the
difference between the primary substance flow and the residual primary
substance flow in terms of the content of first substance. The desired
value for the content of the carrier particles in the residual primary
substance flow is preferably zero. The desired value for the content of
the first substance in the residual primary substance flow is preferably
equal to the content of the first substance in the primary substance
flow.

[0030] The parameters of the demixing are preferably set so as to decrease
the change of the content depending on the predetermined variation, in
particular the magnitude of the change. A decrease in the case of an
identical predetermined variation signifies that the demixing of the
agglomerates, i.e. the magnetic carrier particles being detached from the
first substance, is decreased. The parameters of the demixing are
preferably set such that the change of the content of first substance in
the secondary substance flow depending on the predetermined variation
tends towards zero.

[0031] The demixing is optimally set when the content proportion in the
secondary substance flow lies in a range which is conditioned by the
degree to which the first substance is physically dragged along by the
flow during the precipitation of the magnetic carrier particles. This
means that the proportion of the first substance in the secondary
substance flow is no longer conditioned by a superficial bond of the
carrier particle to the first substance, but by the flow conditions in
the precipitation. However, the physical loading can still vary depending
on the selected deposition conditions, and can also be influenced by
their setting.

[0032] The first substance is preferably a non-magnetic ore or a DNA
sequence. The method can therefore be used both in the field of raw
materials extraction and in the field of biotechnology.

[0033] In this case, the primary substance flow is an ore-bearing sludge
or a solution containing DNA sequences.

[0034] A control unit for a device for separating a first substance from a
flowable primary substance flow may use machine-readable program code
with control instructions which, when executed, cause the control unit to
perform the method.

[0035] The device separates a first substance from a flowable primary
substance flow by a demixing unit and/or a mixing unit, a precipitation
unit and a control unit, where the demixing unit and/or the mixing unit
and the precipitation unit have an active connection to the control unit.

[0036] Machine-readable program code for a control unit includes control
instructions which cause the control unit to perform the method and are
stored on a storage medium.

BRIEF DESCRIPTION OF THE DRAWINGS

[0037] These and other aspects and advantages will become more apparent
and more readily appreciated from the following description of an
exemplary embodiment which is explained in greater detail with reference
to the accompanying schematic drawings, in which:

[0038]FIG. 1 is a schematic block diagram of a separating device having a
mixing unit and a precipitation unit,

[0039]FIG. 2 is a graph of an exemplary profile of the content of a first
substance, e.g. ore, in a secondary substance flow depending on a
parameter which influences the magnetic forces in the context of a "load
method",

[0040]FIG. 3 is a flow diagram to illustrate a schematic execution of the
method in the context of a "load method",

[0041]FIG. 4 is a schematic block diagram of a separating device having a
demixing unit and a precipitation unit,

[0042]FIG. 5 is a graph of an exemplary profile of the content of a first
substance, e.g. ore, in a secondary substance flow depending on a
parameter which influences the magnetic forces in the context of an
"unload method",

[0043]FIG. 6 is a flow diagram to illustrate a schematic execution of an
embodiment of the separation method in the context of a "unload method".

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0044] Reference will now be made in detail to the preferred embodiments,
examples of which are illustrated in the accompanying drawings, wherein
like reference numerals refer to like elements throughout.

[0045]FIG. 1 shows an exemplary schematic illustration of a separating
device 1 for separating a first substance S1 from a flowable substance
mixture containing the first substance S1.

[0046] The separating device 1 can take the form of an integrated device
as often found in the field of biotechnology due to the small volumes.
However, the separating device 1 (including e.g. large-scale
installations) can be divided into physically distinct units as is
customary in mining applications, for example.

[0047] The figures are now explained in greater detail, taking as an
example the use of the separating device 1 and the separation method in
mining. However, the method is not restricted to mining applications.

[0048] The separating device 1 shown in FIG. 1 is used to separate a first
substance S1, being particles of a non-magnetic ore in the present
exemplary case, e.g. CuS or other copper-bearing ores which are likewise
referred to as S1 in the following, from a flowable substance mixture by
magnetic carrier particles M. Depending on the process stage, the
substance mixture has an increased proportion of dead rock which must be
separated from the ore.

[0049] For this purpose, the crushed and normally pretreated ore in the
form of ore particles S1 and magnetic carrier particles M are mixed
together in a mixing unit 2 in such a way that the ore particles S1 and
the carrier particles M are bound to each other. This is achieved e.g. by
selective surface activation of the ore particles S1 and the magnetic
carrier particles M. The carrier particles M bond selectively to the ore
particles S1 as a result and agglomerates MS1 of ore plus carrier
particles are produced. However, due to the selectivity, the dead rock
does not bond to the magnetic carrier particles M.

[0050] The bonding of the carrier particles M to the ore particles S1
significantly influences the economic efficiency that can be achieved
when separating the ore from the dead rock.

[0051] After the ore particles S1 and the magnetic carrier particles M
have been mixed accordingly, the substance mixture known as primary
substance flow P, which in the present example usually is an aqueous
suspension of dead rock, agglomerates MS1 of ore plus carrier particles,
and possibly still unbound ore particles S1 and still unbound carrier
particles M, is supplied to a precipitation unit 3.

[0052] A separation of the agglomerates MS1 of ore plus carrier particles
from the suspension, also referred to as sludge, is performed in the
precipitation unit 3 with the aid of magnetic forces which can be
directly or indirectly set, and optionally with the aid of further
deposition conditions.

[0053] As a result of the precipitation, the primary substance flow P is
divided into a secondary substance flow S(MS1), which is enriched with
agglomerates MS1 of ore plus carrier particles, and a residual primary
substance flow R containing mainly dead rock. The dead rock and any ore
that is not bound to carrier particles are not removed in the secondary
substance flow S(MS1) and remain in the residual primary substance flow
R.

[0054] In the ideal scenario, preferably all ore particles S1 bond to
magnetic carrier particles M in the mixing, in order that they can be
separated generally from the substance mixture by magnetic forces in the
precipitation.

[0055] The above method is referred to as a "load method", since the
magnetic carrier particles M must first be "loaded" with the ore
particles S1 in order to separate the ore particles S1 from the substance
mixture.

[0056] In order to influence the mixing and the precipitation, the mixing
unit 2 and the precipitation unit 3 are actively connected to a control
unit 4. The operating parameters of the mixing unit 2 and of the
precipitation unit 3 can be set by the control unit 4.

[0057] The control unit 4 includes machine-readable program code 6 in the
form of control instructions that cause the control unit 4 to perform a
corresponding embodiment of the method.

[0058] The machine-readable program code 6 can be transferred to the
control unit 4 as a stored program by a data storage medium 5 such as
e.g. a CD, DVD, flash storage medium such as USB stick, or similar.
Alternatively the program code 6 can also be transferred to the control
unit 4 by a network connection.

[0059]FIG. 2 shows a qualitative illustration of the profile of the ore
content in the secondary substance flow S(MS1), this being enriched with
agglomerates MS1 of ore plus carrier particles, which can be achieved
when a "load method" is performed. This means that the first substance is
loaded onto a magnetic carrier particle M, such that the separation of
the non-magnetic first substance from the substance mixture is actually
possible by magnetic forces.

[0060] The variation of the parameter influencing the magnetic forces is
implemented in this exemplary case by changing the magnetic flux density
B, e.g. by influencing a current flow in a coil which generates a
magnetic field and in turn has a direct influence on the magnetic forces
acting in the precipitation unit 3. The current generating the magnetic
field or the force itself could also be plotted on the X-axis, for
example. A distance of the magnets from the wall of the precipitation
unit 3 can also be varied, for example, in order to influence the
magnetic forces acting on the magnetic carrier particles M or on the
agglomerates MS1 of ore plus carrier particles.

[0061] It is important that the parameter which conditions the variation
can be set selectively, and for the corresponding variation of the
parameter which influences the magnetic forces also to be repeatable. In
this case, the variation must take place in such a way that a measurable
influence over the content of ore in the secondary substance flow S(MS1)
is produced.

[0062] The illustrated curves of the ore content G in the secondary
substance flow S(MS1) depending on the magnetic flux density B are
parameterized according to different operating states, which specify the
degrees of bonding of ore to carrier particles and are significantly
influenced in the mixing unit 2.

[0063] In this case, a degree of bonding is understood to mean the ratio
of the proportion of ore particles S1 that are bound to magnetic carrier
particles M to the total ore content of the substance mixture. If all of
the ore particles S1 were bound to magnetic carrier particles M, the
degree of bonding would be maximal, i.e. 1.

[0064] In this case, M1 represents a first operating state (i.e. a set of
operating parameters) of the mixing unit 2, in which a first
(comparatively low) degree of bonding of the ore particles S1 to the
carrier particles M is achieved. In this case, irrespective of the
configuration of the precipitation unit, only a low content of
agglomerates of ore plus carrier particles can be achieved in the
secondary substance flow, since only comparatively few ore particles of
the total ore particles S1 present in the sludge are bound to magnetic
carrier particles M and therefore only these bound ore particles S1 can
be removed from the primary substance flow P by magnetic forces.

[0065] In a similar manner, M2, M3 and M4 represent a second, third and
fourth operating state of the mixing unit 2, in which a second, third or
fourth degree of bonding of the ore to the carrier particles M is
achieved. The degrees of bonding increase in each case for the respective
operating states M1 to M4. In other words, very good bonding of the ore
particles S1 to the carrier particles M is achieved as a result of the
mixing in the fourth operating state M4, while the bonding that results
from the mixing in the third operating state M3 or in the second and
first operating states M2, M1 decreases steadily. In respect of the
illustrated diagram, the same initial suspension is provided for all
mixing states in this case, i.e. the proportion of ore that can be bound
to magnetic carrier particles in the suspension is identical for all
mixing states.

[0066] In order to achieve maximal economic efficiency of the separation
method, the highest possible degree of bonding of the ore to the magnetic
carrier particles M must be ensured, i.e. as many ore particles S1 as
possible should be bound to carrier particles after passing through the
mixing unit 2. Ideally (though normally impossible since the crushing of
the ore is finite, i.e. the dead rock still includes ore), no separable
ore should remain isolated from magnetic carrier particles M.

[0067]FIG. 3 describes a schematic execution of the method for an
exemplary embodiment of the method.

[0068] In 100, mixing of the ore particles S1 and of the magnetic carrier
particles M takes place using known operating parameters. In particular,
the following are known:

[0069] content and type of the magnetic
carrier particles M in the sludge and/or quantity and type of added
carrier particles M;

[0074] If the method is not yet in progress, the mixing is initialized
using specified parameters.

[0075] In 101 following thereupon, precipitation of the agglomerates of
ore plus carrier particles takes place to the extent possible under the
prevailing boundary conditions. At this time, a precipitation of
agglomerates generally takes place which could nonetheless be improved.

[0076] In 102 following thereupon, a selective and predetermined variation
of a parameter which influences the magnetic precipitation takes place,
e.g. the magnitude of the parameter. The parameter may differ according
to the precipitation unit 3 in use. The precipitation unit 3 may include
electromagnets whose properties can be deterministically influenced by
the current flowing through them. Examples include the:

[0077] setting
of magnetic precipitation parameters (depending on the magnet systems in
use) such as flow density, distance from the sludge, and

[0078] in the
case of electromagnetic precipitation equipment which may be used, and
particularly in the case of magnetic travelling field separators:

[0079] signal excitation form/frequency/phase position of the current of
coils relative to each other, etc.;

[0080] signal amplitude;

[0081]
relative signal profile of a travelling field that may be present, in
relation to the flow of the sludge (opposition/synchronicity/speed), etc.

[0082] The change of the magnetic forces that is conditioned by the
variation of the parameter causes a change of the content of ore
particles S1 in the secondary substance flow S(MS1). This change is
captured by a measuring entity in 103.

[0083] On the basis of the captured change of the content of the ore in
the secondary substance flow S(MS1) and with reference to the parameter
variation that caused the content change, the change of the content
depending on the predetermined variation is determined. This takes place
in 104.

[0084] In 105, the obtained value is now compared with a reference value
in the form of a first threshold value SW1 which exists for a
corresponding parameter variation.

[0085] The first threshold value SW1 can be generated dynamically, for
example. The first threshold value SW1 can therefore be e.g. the maximal
magnitude that has been achieved during live operation in respect of the
change of the content depending on the parameter variation.

[0086] In this case, the deposition conditions initially remain
essentially constant. Before optimization of the precipitation,
"self-optimization" takes place in respect of the first threshold value
SW1, since it is a continuous objective to exceed the previously achieved
maximal value when processing the available ore by changing the mixing
parameters.

[0087] In a so-called calibration phase at the start, the first threshold
value SW1 may be maximized as far as possible by changing the operating
parameters of the mixing unit 2, wherein e.g. a specific calibration time
that must be satisfied, or a static or possibly ore-dependent minimal
threshold value that must be achieved, has been predefined. During
subsequent live operation, "fine tuning" of the threshold value always to
maximal values of the change of the content depending on the parameter
variation can take place at the respectively current working point of the
separating device 1.

[0088] Such a calibration method may be performed in a closed circuit for
the flows, i.e. the generated secondary substance flow S(MS1) and the
residual primary substance flow R are fed back into the mixing unit. No
material losses occur during the calibration phase as a result of this,
but the respective mixing conditions are continuously reflected in the
agglomerates of ore plus carrier particles.

[0089] Alternatively, a first threshold value SW1 can be taken from a
database. In this case, the first threshold value SW1 should be
compatible with the ore that is to be processed and the corresponding
working point, i.e. comparable or at least similar initial conditions
should be present before the separation method is started (e.g.
approximately identical ore to be separated, similar grain size
distribution of the ore, similar ore content in the gangue etc.), and
similar deposition conditions.

[0090] If the first threshold value SW1 is not exceeded, the mixing
parameters are set. It is endeavored to set the mixing parameters such
that the change of the content of ore particles S1 depending on the
predetermined variation increases in comparison with a previously
achieved value, in particular such that the first threshold value SW1 is
exceeded, since this signifies that the degree of bonding of the ore to
the magnetic carrier particles M has increased. By virtue of this method,
it is possible to switch from a curve as illustrated in FIG. 2 having a
specific parameter set which corresponds to the operating state M2 and a
corresponding degree of bonding, to a curve with an improved degree of
bonding, e.g. having a parameter set which corresponds to an operating
state M3.

[0091] The optimization of the mixing and of the precipitation may take
place at different times. However, the optimization can take place
alternately or switch between the mixing and the precipitation depending
on the currently achieved threshold value, wherein optimization can be
focused on the precipitation or the mixing depending on the currently
achieved threshold value.

[0092] If a minimal threshold value for the change of the content of the
ore in the secondary substance flow S(MS1) depending on the parameter
variation is reached, the operation of the precipitation unit is then
optimized in the context of a serial approach. In the present example,
this is queried in 106.

[0093] The capture and determination of the ore content in the secondary
substance flow S(MS1) for the optimization of the precipitation takes
place in 107. If the bonding of the ore to the magnetic carrier particles
M is maximized, the economic efficiency of the separation method is then
essentially dependent only on the operating parameters of the
precipitation.

[0094] In 108, the determined ore content is compared with a reference
value in the form of a second threshold value SW2 for the ore content.
The operating parameters of the precipitation unit 3 are set until the
desired second threshold value SW2 is reached or exceeded.

[0095] If both first threshold value SW1 and second threshold value SW2
are exceeded, the separating device 1 can be operated in a steady state
with a high level of economic efficiency.

[0096] The capture of the content and the change of the content of ore
depending on the predetermined parameter variation should nonetheless
take place continuously, in order that the economic efficiency of the
method can be monitored at all times and corresponding control
interventions can be performed if necessary.

[0097]FIG. 4 shows a separating device 1' by which a first substance S1,
which will likewise be a non-magnetic ore in the context of this example,
is separated from a magnetic carrier particle M that carries the first
substance S1.

[0098] To this end, e.g. secondary substance flow S(MS1) with the
agglomerates MS1 of ore plus carrier particles contained therein is
supplied to a demixing unit 2'. In the demixing unit 2', the ore is
detached from the carrier particle M by corresponding operating
parameters, e.g. temperature, pH value and addition of solvents, which
cause the ore particles to become detached from the carrier particle M.
These are therefore present concurrently in a flowable substance flow,
the "new" primary substance flow P(M/S1).

[0099] Similar operating parameters can be set for the demixing unit 2' as
for the mixing unit 2 from FIG. 1, for example:

[0100] parameters for
setting the detachment of the ore particles from the carrier particles
according to the action mechanism used, e.g. concentration of solvent
added, e.g. tensides, polar solvents, or other solvents (according to the
bonding chemistry, etc.), current temperature, pH value, energy input,
etc.;

[0103] The flowable primary substance flow P(M/S1) therefore now contains
ore particles S1 and carrier particles M which are concurrently present
but are no longer bound to each other. The primary substance flow P(M/S1)
enters the precipitation unit 3. The precipitation unit 3 includes a unit
for generating magnetic fields, by which a magnetic force is applied to
the carrier particles M, such that the primary substance flow P(M/S1) is
divided into a secondary substance flow S enriched with carrier particles
M and a residual primary substance flow R enriched with ore particles S1.
Ideally, no ore particles S1 are now contained in the secondary substance
flow S and no carrier particles M are now contained in the residual
primary substance flow R. However, this is not possible in practice. In
practice, the objective is to minimize the content of carrier particles M
in the residual primary substance flow R and the ore content in the
secondary substance flow S.

[0104] In the present example, a control unit 4 is actively connected to
the demixing unit 2' and the precipitation unit 3, in order that it can
obtain information about the operating state, e.g. from data that has
been captured, and actively perform control interventions on the demixing
unit 2' and/or precipitation unit 3. In a similar manner to the
explanations regarding FIG. 1, the control unit 4 has machine-readable
program code 6 which is transferred to the control unit 4 in the manner
of a stored program by a data storage medium 5 or by a network
connection, for example.

[0105]FIG. 5 shows a diagram in which curves describe the content of the
proportion of ore in the secondary substance flow depending on the
magnetic flux density B. The different curves show the ore content for
different operating states E1 to E4 of the demixing unit 2', i.e.
parameterized according to a degree of detachment.

[0106] A degree of detachment designates the ratio of previously bound ore
particles S1, which are now detached from the carrier particle M, to the
total ore content of the substance flow. The degree of detachment should
ideally be 1, i.e. no ore particles S1 should be bound to the carrier
particles M after passing through the demixing.

[0107] If the ore particles S1 are detached from the agglomerates of ore
plus carrier particles in such a way that ore particles and carrier
particles are present concurrently but are no longer bound to each other,
it can be expected that hardly any change of the ore content in the
secondary substance flow S(M) will occur as a result of a predetermined
variation of a parameter which influences the magnetic forces. Mainly
carrier particles M are removed in the secondary substance flow S(M).
Only those ore particles S1 which are physically enclosed by the carrier
particles M or dragged along by the carrier particles M are contained in
the secondary substance flow S(M). Consequently, the degree of detachment
in operating state E1 is greater than in the curve for the operating
states E2, E3 or E4. E1, E2, E3 and E4 respectively characterize a first,
second, third and fourth operating state of the demixing unit 2', by
which operating states different degrees of detachment are achieved for
the agglomerates MS1 of ore plus carrier particles.

[0108] In the case of the curve associated with the operating state E4, a
considerable proportion of agglomerates MS1 of ore plus carrier particles
is still present. If such a case occurs, it is beneficial to feed the
secondary substance flow S(M) back into the demixing unit 2' in order
again to effect a detachment of the ore particles S1 from the carrier
particles M. Further processing of the carrier particles M in the
secondary substance flow S(M) in the case of an increased proportion of
ore particles is disadvantageous to the economic efficiency of the
method, since the ore contained in the secondary substance flow S(M)
cannot readily be supplied to the further operations for ore preparation.
Furthermore, the ore presents problems during the preparation of the
carrier particles for reuse in a separation method which is performed
subsequently. The degree of detachment decreases for the operating states
E1 to E3, i.e. only ore particles S1 that are e.g. physically loaded
remain in the secondary substance flow S(M) in the context of E1.

[0109] Moreover, it is advantageous likewise to determine the proportion
of carrier particles in the residual primary substance flow R(S1). This
can be effected by the magnetization of the carrier particles M and a
corresponding coil arrangement, for example. It is thereby possible to
determine whether the precipitation unit 3 is optimally set. If this is
the case, the secondary substance flow S(M) will be enriched with both
undisrupted agglomerates MS1 of ore plus carrier particles and the
carrier particles M which have been detached from the ore. However, if
significant quantities of carrier particles M remain in the residual
primary substance flow R(S1), this indicates that the operation of the
precipitation unit 3 must be improved. This measurement is not
illustrated in the figures.

[0110]FIG. 6 shows a flow diagram representing a schematic illustration
of an exemplary execution of the method.

[0111] In 100' demixing takes place in the demixing unit 2' of the
separating device 1'. The bonds between ore particles S1 and carrier
particles M are disrupted here. This is achieved e.g. by the addition of
corresponding chemicals suited to the bonding chemistry that was used to
generate the bond between ore particles S1 and carrier particles M. Other
mechanisms can also be used to effect a disruption. The primary substance
flow P(M/S1) therefore contains, separately, ore particles S1 and carrier
particles which are no longer bound to each other; see FIG. 4.

[0112] In 101 following thereupon, the precipitation of the carrier
particles M and ore particles S1 that are present in detached form is
effected by magnetic forces in the precipitation unit 3. The secondary
substance flow S(M) is enriched with carrier particles M. The residual
primary substance flow R(S1) is enriched with ore particles S1.

[0113] In 102, a predetermined variation is effected in respect of the
parameters which influence the magnetic forces for the precipitation. The
explanations given above apply similarly here.

[0114] The change of the content of ore particles S1 in the secondary
substance flow S(M), caused by the variation of the parameter/parameters,
is captured in 103 and, on the basis of this, the change of the content
of ore particles S1 depending on the variation is determined in 104.

[0115] A comparison is then made between the determined change of the
content of ore particles S1 depending on the variation. The lower the
determined change of the content of ore particles S1 depending on the
variation made, the more effectively the ore particles S1 have been
detached from the carrier particles M. Ideally, a parameter variation of
the magnetic forces has little or no influence on the ore content in the
secondary substance flow S(M). It is therefore endeavored to achieve a
value of essentially 0, over the entire parameter range, in respect of
the change of the ore content depending on the predetermined parameter
variation. Due to a possible change of the physical loading resulting
from the parameter variation which influences the magnetic forces, a
reference value in the form of a first threshold value SW1' greater than
zero should nonetheless be selected, though this should be so low that it
merely allows for any eventual change of the physical loading as a result
of the variation. This means that the first threshold value SW1' is
exceeded as soon as agglomerates MS1 of ore plus carrier particles are
present in a specific and no longer insignificant concentration in the
primary substance flow P(M/S1).

[0116] In particular, a factor greater than or equal to 1 can also be
multiplied by the ore content corresponding to the natural limit
(resulting from physical loading), in order to generate a threshold value
that must not be exceeded. At the same time, it is advantageous to
determine the content of the ore in the secondary substance flow S(M).
This should be essentially constant over the entire parameter range, e.g.
the range of flow density B, and conditioned solely by the physical
loading of ore.

[0117] Previously determined and achievable values for the ore content in
the secondary substance flow S(M), which demonstrably result in good
economic efficiency of the method, can also be used as first threshold
values SW1'.

[0118] This applies similarly to the proportion of carrier particles in
the residual primary substance flow R(S1). Ideally, the residual primary
substance flow R(S1) should no longer contain any carrier particles M. If
a change of a parameter which influences the magnetic forces also results
in a change of the content of carrier particles M in the residual primary
substance flow R(S1), this indicates that the precipitation unit 3 is not
being optimally operated and carrier particles M are being lost. In
respect of the carrier particles M in the residual primary substance flow
R(S1), however, the content (i.e. the relative or absolute content) of
carrier particles M in the residual primary substance flow R(S1) may be
determined. This can be effected e.g. by a corresponding coil
arrangement, which uses the magnetization of the carrier particles M as a
basis for measurement.

[0119] If the threshold value of the ore content in the secondary
substance flow S(M) is reached or exceeded in 105, provision is made in
106 for setting the operating parameters of the demixing unit 2' in order
to achieve a better detachment of ore particles S1 and carrier particles
M. The secondary substance flow S(M) and the residual primary substance
flow R(S1) may be fed back into the demixing unit 2' until the first
threshold value SW1' is no longer exceeded.

[0120] In 107, provision is now made for capturing the content of the
carrier particles M in the residual primary substance flow R(S1). In 108,
this is then compared with a reference value in the form of a second
threshold value SW2'. The second threshold value SW2' specifies the
maximal loss that is acceptable to the operator in respect of carrier
particles M in the residual primary substance flow R(S1), which in this
example is essentially of an aqueous suspension with ore particles S1.

[0121] The loss of carrier particles M also has a considerable influence
on the economic efficiency of the method, since the carrier particles M
contained in the residual primary substance flow R(S1) must be replaced
sooner or later. Therefore a second threshold value SW2' is usually
selected which represents 1% or less of the quantity of carrier particles
M in use. However, the selection of the second threshold value SW2' can
be adapted according to the first substance S1 and the carrier particles
M that are used.

[0122] If the second threshold value SW2' for the carrier particles M is
reached or exceeded, the deposition conditions are adapted in 109 in
order to improve the removal of the carrier particles M from the primary
substance flow P(M/S1) and to reduce the content of the magnetic carrier
particles M in the residual primary substance flow R(S1) to below the
second threshold value SW2', such as to zero.

[0123] The entire method may be executed and continuously optimized as a
method that is controlled by a control unit 4, e.g. the purity of the
secondary substance flow S(M) and of the residual primary substance flow
R(M) is maximized, wherein consideration is given to the coupling of the
flows such that the separating device 1' is operated with optimal
economic efficiency.

[0124] It is not normally possible simultaneously to maximize the purity
of both flows, i.e. secondary substance flow S(M) and residual primary
substance flow R(S1), even though this may be desirable. The optimization
is therefore applied to that combination of purity in both flows which is
most advantageous in terms of economic efficiency. This can depend in
particular on the price of ore and on the price of the magnetic carrier
particles M.

[0125] A description has been provided with particular reference to
preferred embodiments thereof and examples, but it will be understood
that variations and modifications can be effected within the spirit and
scope of the claims which may include the phrase "at least one of A, B
and C" as an alternative expression that means one or more of A, B and C
may be used, contrary to the holding in Superguide v. DIRECTV, 358 F3d
870, 69 USPQ2d 1865 (Fed. Cir. 2004).